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Manual Moteur S3L2 Mitsubishi - Copie
Manual Moteur S3L2 Mitsubishi - Copie
This service manual has instructions and procedures for the Mitsubishi SL-series diesel engines.
The information, specifications and illustrations in this manual are on the basis of the information that was current at
the time this issue was written.
Correct servicing, test and repair procedures will give the engine a long service life. Before starting a test, repair or
rebuild job, the serviceman must read the respective sections of this manual to know all the component he will work
on.
Continuing improvement of product design may have caused changes to your engine which are not included in this
manual.
Whenever a question arises regarding your engine, or this manual, consult your Mitsubishi dealer for the latest
available information.
Service Manual
Mitsubishi SL-Series diesel engines
Version 08/2004
Copyright © 2004 MHI Equipment Europe B.V.
HOW TO USE THIS MANUAL
Exploded views
In the exploded views, the component parts are separated but so arranged to show their relationship to the whole.
Index numbering is used to identify the parts and to indicate a sequence in which the parts are to be removed for
disassembly, or they are to be installed for assembly.
Symbols
The following symbols are used in this manual to emphasize important and critical instructions:
NOTE
Indicates a condition that can cause engine damage
CAUTION
Indicates a condition that can cause personal injury or
WARNING death.
Tightening torques
Tighten bolts, nuts, etc. in a wet condition (apply oil to threads) when specified as [WET]. Tighten them in a dry
condition unless so specified. Use the general tightening torques unless otherwise specified.
TABLE OF CONTENTS
TABLE OF CONTENTS
GENERAL INFORMATION
1 MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION.................................................... 10
1.1 Model identification location................................................................................................... 10
1.2 Serial Number Location ......................................................................................................... 11
2 COMPONENT LOCATION.............................................................................................................. 12
2.1 S3L/S3L2 ............................................................................................................................... 12
2.2 Engine S3L-T/S3L2-T ............................................................................................................ 13
2.3 S4L/S4L2 ............................................................................................................................... 14
2.4 Engine S4L-T/S4L2-T ............................................................................................................ 15
3 SPECIFICATIONS .......................................................................................................................... 16
OVERHAUL INSTRUCTIONS
4 DETERMINING WHEN TO OVERHAUL THE ENGINE ................................................................. 18
5 COMPRESSION PRESSURE MEASUREMENT............................................................................ 19
5.1 Inspection............................................................................................................................... 19
5.2 Measurement ......................................................................................................................... 19
6 TROUBLESHOOTING .................................................................................................................... 20
6.1 General .................................................................................................................................. 20
6.2 Engine troubleshooting .......................................................................................................... 21
6.3 Starting system troubleshooting............................................................................................. 27
7 BASIC PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY................................................... 29
7.1 Disassembly........................................................................................................................... 29
7.2 Assembly ............................................................................................................................... 29
DISASSEMBLY
8 PREPARATION FOR DISASSEMBLY............................................................................................ 32
8.1 Engine oil draining ................................................................................................................. 32
8.2 Coolant draining 1 .................................................................................................................. 32
9 ELECTRICAL SYSTEM .................................................................................................................. 33
9.1 Starter .................................................................................................................................... 33
9.2 Alternator ............................................................................................................................... 35
10 Cooling System ............................................................................................................................... 38
10.1 Cooling fan removal ............................................................................................................... 38
10.2 Thermostat case removal ...................................................................................................... 38
10.3 Water pump assembly removal ............................................................................................. 38
11 Fuel System .................................................................................................................................... 39
11.1 Fuel injection pipe removal .................................................................................................... 39
11.2 Fuel injection nozzle removal................................................................................................. 39
11.3 Governor assembly removal .................................................................................................. 39
11.4 Governor weight removal....................................................................................................... 40
11.5 Fuel injection pump removal .................................................................................................. 40
12 Lubrication System.......................................................................................................................... 41
12.1 Oil filter removal ..................................................................................................................... 41
12.2 Pressure relief valve removal................................................................................................. 41
12.3 Oil pressure switch removal................................................................................................... 41
13 AIR INLET SYSTEM AND EXHAUST SYSTEM ............................................................................. 42
13.1 Exhaust manifold removal...................................................................................................... 42
13.2 Air inlet cover removal ........................................................................................................... 42
14 CYLINDER HEAD AND VALVE MECHANISM ............................................................................... 43
14.1 Rocker shaft assembly removal............................................................................................. 44
14.2 Rocker shaft disassembly ...................................................................................................... 44
14.3 Cylinder head bolt removal .................................................................................................... 44
14.4 Cylinder head assembly removal........................................................................................... 45
14.5 Valve and valve spring removal ............................................................................................. 45
14.6 Valve stem seal removal........................................................................................................ 45
15 Timing Gears and Flywheel............................................................................................................. 46
TABLE OF CONTENTS
INSPECTION
17 CYLINDER HEAD AND VALVE MECHANISM ............................................................................... 58
17.1 Cylinder head......................................................................................................................... 59
17.2 Rocker arms and rocker shaft................................................................................................ 59
17.3 Valve springs ......................................................................................................................... 60
17.4 Valve push rods ..................................................................................................................... 60
17.5 Valves, valve guides and valve seats .................................................................................... 60
17.6 Combustion jet replacement .................................................................................................. 64
18 TIMING GEARS AND FLYWHEEL ................................................................................................. 66
18.1 Camshaft................................................................................................................................ 67
18.2 Fuel injection pump camshaft ................................................................................................ 68
18.3 Tappets .................................................................................................................................. 69
18.4 Idler gear................................................................................................................................ 69
18.5 Flywheel and ring gear........................................................................................................... 70
19 CYLINDER BLOCK, CRANKSHAFT, PISTONS AND OIL PAN ..................................................... 71
19.1 Pistons, Piston Rings and Piston Pins ................................................................................... 72
19.2 Connecting rods..................................................................................................................... 74
19.3 Crankshaft.............................................................................................................................. 75
19.4 Cylinder block ........................................................................................................................ 79
ASSEMBLY
20 Cylinder Block, Crankshaft, Pistons and Oil pan............................................................................. 82
20.1 Main bearing installation ........................................................................................................ 83
20.2 Crankshaft installation............................................................................................................ 83
20.3 Main bearing cap installation ................................................................................................. 83
20.4 Side seal installation .............................................................................................................. 85
20.5 Piston assembling to connecting rod ..................................................................................... 85
20.6 Piston ring installation ............................................................................................................ 87
20.7 Piston and connecting rod installation ................................................................................... 87
20.8 Connecting rod cap installation.............................................................................................. 88
20.9 Oil screen installation............................................................................................................. 89
20.10Oil pan installation.................................................................................................................. 89
21 Timing Gears and Flywheel............................................................................................................. 91
TABLE OF CONTENTS
ELECTRICAL SYSTEM
28 GENERAL ..................................................................................................................................... 112
28.1 Specifications (standard) ..................................................................................................... 112
28.2 Wiring diagrams ................................................................................................................... 113
29 STARTER...................................................................................................................................... 115
29.1 Disassembly......................................................................................................................... 115
29.2 Inspection............................................................................................................................. 116
29.3 Assembly ............................................................................................................................. 119
29.4 Inspection and Testing after Assembly ................................................................................ 120
30 ALTERNATOR .............................................................................................................................. 122
TABLE OF CONTENTS
COOLING SYSTEM
34 GENERAL ..................................................................................................................................... 136
34.1 Schematic ............................................................................................................................ 136
34.2 Specifications (standard) ..................................................................................................... 136
35 INSPECTION ................................................................................................................................ 137
35.1 Water pump ......................................................................................................................... 138
35.2 Thermostat (standard) ......................................................................................................... 138
35.3 Thermoswitch (standard) ..................................................................................................... 139
35.4 Thermounit (standard) ......................................................................................................... 139
LUBRICATION SYSTEM
36 GENERAL ..................................................................................................................................... 142
36.1 Schematic ............................................................................................................................ 142
36.2 Specifications....................................................................................................................... 142
37 INSPECTION ................................................................................................................................ 143
37.1 Oil pump............................................................................................................................... 143
37.2 Oil pressure switch............................................................................................................... 143
37.3 Pressure relief valve ............................................................................................................ 144
FUEL SYSTEM
38 GENERAL ..................................................................................................................................... 146
38.1 Schematic ............................................................................................................................ 146
38.2 Specifications (standard) ..................................................................................................... 147
39 FUEL INJECTION NOZZLE .......................................................................................................... 148
39.1 Inspection............................................................................................................................. 148
39.2 Disassembly and assembly ................................................................................................. 150
40 FUEL INJECTION PUMP.............................................................................................................. 151
40.1 Test on engine ..................................................................................................................... 151
40.2 Disassembly......................................................................................................................... 151
40.3 Inspection............................................................................................................................. 155
40.4 Assembly ............................................................................................................................. 156
41 GOVERNOR ................................................................................................................................. 159
41.1 Disassembly and inspection ................................................................................................ 159
41.2 Assembly ............................................................................................................................. 160
41.3 Torque spring set installation ............................................................................................... 161
42 FUEL PUMP.................................................................................................................................. 162
42.1 Inspection............................................................................................................................. 162
43 FUEL FILTER................................................................................................................................ 163
MAINTENANCE
46 LUBRICATION AND MAINTENANCE CHART ............................................................................. 170
47 ENGINE OIL AND OIL FILTER ..................................................................................................... 172
47.1 Engine oil specifications....................................................................................................... 172
47.2 Oil level check...................................................................................................................... 172
47.3 Oil and oil filter change ........................................................................................................ 173
47.4 Oil filter change .................................................................................................................... 173
48 VALVE CLEARANCE.................................................................................................................... 175
49 FUEL INJECTION TIMING............................................................................................................ 177
49.1 Preparation .......................................................................................................................... 177
49.2 Adjustment ........................................................................................................................... 179
50 FUEL FILTER................................................................................................................................ 180
50.1 Fuel filter with [AIR] valve .................................................................................................... 180
50.2 Cartridge (air vent screw) type fuel filter .............................................................................. 180
51 FUEL SYSTEM PRIMING ............................................................................................................. 181
51.1 Engine with fuel filter with [AIR] valve .................................................................................. 181
51.2 Engine with cartridge (air vent screw) type fuel filter ........................................................... 181
52 IDLE RPM SETTING..................................................................................................................... 182
53 FUEL INJECTION NOZZLES........................................................................................................ 183
53.1 Injection pressure (valve opening pressure) test ................................................................. 183
53.2 Orifice restriction test ........................................................................................................... 183
53.3 Nozzle tip washing and replacement ................................................................................... 183
53.4 Installation............................................................................................................................ 183
54 FAN BELT ..................................................................................................................................... 184
SERVICE DATA
55 SPECIFICATIONS ........................................................................................................................ 186
55.1 Basic engine components.................................................................................................... 186
55.2 Lubrication system ............................................................................................................... 188
55.3 Fuel system.......................................................................................................................... 188
55.4 Air inlet system and exhaust system.................................................................................... 188
55.5 Cooling system (standard) ................................................................................................... 189
55.6 Electrical system .................................................................................................................. 189
56 TIGHTENING TORQUES ............................................................................................................. 191
56.1 Major bolts and nuts............................................................................................................. 191
56.2 Torques for bolts and nuts with standard threads................................................................ 192
56.3 Torques for plugs with taperlock threads ............................................................................. 192
57 SEALANTS.................................................................................................................................... 193
58 SPECIAL TOOLS .......................................................................................................................... 194
TABLE OF CONTENTS
GENERAL INFORMATION
MODEL IDENTIFICATION AND SERIAL
NUMBER LOCATION General
General
1 MODEL
IDENTIFICATION AND
SERIAL NUMBER
LOCATION
1.1 Model identification location
t
Displacement
S 4 L (2) – 61 A
61 - Export code
A - Specification code
MODEL IDENTIFICATION AND SERIAL
General NUMBER LOCATION
Serial number
GENERAL INFORMATION
2 COMPONENT
LOCATION
2.1 S3L/S3L2
Hanger
Oil filler
Air vent screw
Fuel injection nozzle
Water pump
Stop solenoid
Oil filler
Fuel filter
REAR FRONT
RIGHT SIDE VIEW
Thermoswitch
Hanger
Flywheel housing
Alternator
Starter
Fan
Flywheel
V-belt
Oil pan
FRONT REAR
Water pump
Stop solenoid
Oil filler
Fuel filter
REAR FRONT
Thermoswitch
RIGHT SIDE VIEW
Turbocharger
Hanger
Flywheel housing
Alternator
Starter
Fan
V-belt Flywheel
Oil pan
FRONT REAR
2.3 S4L/S4L2
Water pump
Stop solenoid
Oil filler
Fuel filter
Thermoswitch
Hanger
Flywheel housing
Alternator
Starter
Fan
Flywheel
V-belt
Oil pan
Oil filler
Fuel filter
Hanger
Flywheel housing
Alternator
Starter
Fan
Flywheel
V-belt
Oil pan
GENERAL INFORMATION
3 SPECIFICATIONS1
Model
System Item
S3L S3L-T S3L2 S3L2-T S4L S4L-T S4L2 S4L2-T
No. of cylinders 3 4
Compression ratio 22
Dry weight (kg) 135 139 135 139 155 159 155 159
Battery
12V, 65 Ah or more 12V, 80 Ah or more
(capacity depends on application)
Table 1 Specifications
OVERHAUL INSTRUCTIONS
4 DETERMINING WHEN
TO OVERHAUL THE
ENGINE
Generally, when to overhaul the engine is to be
determined by taking into account a drop in
compression pressure as well as an increase in lube oil
consumption and excessive blowby gases.
OVERHAUL INSTRUCTIONS
5 COMPRESSION
t
PRESSURE
MEASUREMENT
5.1 Inspection
Check to make sure:
5.2 Measurement
t
290
Limit
--
• It is important to measure the compression SL 30 23
pressure at regular intervals to obtain the data on (427) (327)
the gradual change of the compression pressure. [2 942] [2 256]
Compression pressure, kgf/
• The compression pressure would be slightly
cm2 (psi) [kPa]
higher than the standard in a new or overhauled SL2 32 25
engine owing to breaking-in of the piston rings, (455) (356)
valve seats, etc. It drops as the engine [3 138] [2 452]
components wear down.
Maximum permissible difference 3 --
between average compression (42.7)
pressure of all cylinders in one
engine, kgf/cm2 (psi) [kPa] [294]
TROUBLESHOOTING OVERHAUL INSTRUCTIONS
OVERHAUL INSTRUCTIONS
6 TROUBLESHOOTING
6.1 General
The diagnosis of troubles, especially those caused by a
faulty fuel injection pump or injection nozzles, or low
compression pressure, can be difficult. It requires a
careful inspection to determine not which item is the
cause, but how may causes are contributing to the
trouble, someone of which is the primary cause.
Several causes may be contributing to a single trouble.
2. Inspection procedure
Yes
Are fuel lines free of restriction? (Is fuel pump operating properly when Check fuel filter, fuel lines
No
starter switch in ON position?) and fuel tank.
Yes
Yes
Is fuel injection nozzle discharge pattern normal? Is injection pressure Make adjustment to the
No
correct? nozzles.
Yes
Yes
2. Inspection procedure
Yes
Yes
Is injection pressure (injection nozzle valve opening pressure) correct (not Make adjustment to the
No
too low)? pressure.
Yes
Yes
2. Inspection procedure
Yes
Yes
Are lubrication system components (oil filter, oil pump and oil screen) Check the components and
No
normal and oil level correct? oil level.
Yes
Yes
2. Inspection procedure
Yes
Is injection nozzle discharge pattern normal? Is injection pressure correct Make adjustment to the
No
(not too high)? nozzles.
Yes
Yes
2. Inspection procedure
Yes
Is injection nozzle discharge pattern normal? Is injection pressure Make adjustment to the
No
constant? nozzles.
Yes
Is compression pressure correct (no difference in compression pressure Check valves, piston rings
No
between cylinders)? and cylinder head gasket.
Yes
2. Inspection procedure
Yes
Are fuel lines free from restriction? (Is fuel pump operating properly when Check fuel tank, fuel filter
No
starter switch is in ON position?) and fuel lines.
Yes
Yes
Yes
Yes
Battery run-down
Loose battery terminals
Defective key switch
Pinion fails to Poor S connector contact
shift S connector missing
Open circuit in engine switch coil
Worn starter brushes
Defective contact points in auxiliary switch
Open circuit in auxiliary switch coil
Starter faulty Problems in switch Pull-in and hold-in coils • Burned motor coil
unbalance in number of • Burned pull-in and hold-in coils
windings (minor defect)
Pull-in or hold-in coil layer • Plunger fails to return when
shorted voltage is applied to circuit
Overrun
Contact points defective Switch will not turn off only when engine
fails to fire, resulting in burning of motor
coil
Plunger jammed • Burned motor coil
• Burned pull-in and hold-in coils
Machining fault of parts
Lever pivot jammed Dotted lines indicate failure of contact
Shift lever faulty points to close
Machining fault
Sliding part jammed Sticking pinion metal
Overrunning clutch jammed Sliding surface dirty
Machining fault of lead
Subswitch faulty Burned contact points Burned hold-in coil and motor coil
Assembly fault resulting in
failure to return
External load connected to S circuit Make reference to “Pull-in and hold-in
Incorrect coil unbalance”
wiring S and B circuits shorted Make reference to “Key not returning
completely”
OVERHAUL INSTRUCTIONS
7 BASIC PRECAUTIONS
FOR DISASSEMBLY
AND ASSEMBLY
This section outlines basic precautions recommended
by Mitsubishi that should always be observed.
7.1 Disassembly
1. Always use tools that are in good condition and be
sure you understand how to use them before
performing any job.
2. Use an overhaul stand or a work bench, if
necessary. Also, use bins to keep engine parts in
order of removal.
3. Parts must be restored to their respective
components from which they were removed at
disassembly. This means that all parts must be set
aside separately in groups, each marked for its
component, so that the same combination or set
can be reproduced at assembly.
4. Pay attention to marks on assemblies,
components and parts for their positions or
directions. Put on marks, if necessary, to aid
assembly.
5. Carefully check each part or component for any
sign of faulty condition during removal or cleaning.
The part will tell you how it acted or what was
abnormal about it more accurately during removal
or cleaning.
6. When lifting or carrying a part too heavy or too
awkward for one person to handle, get another
person’s help and, if necessary, use a jack or a
hoist.
7.2 Assembly
1. Wash all parts, except for oil seals, O-rings, rubber
sheets, etc., with cleaning solvent and dry them
with pressure air.
2. Always use tools that are in good condition and be
sure you understand how to use them before
performing any job.
3. Use only good-quality lubricants. Be sure to apply
a coat of oil, grease or sealant to parts as
specified.
4. Be sure to use a torque wrench to tighten parts for
which torques are specified.
5. Any time the engine is assembled, new gaskets
and O-rings must be installed.
BASIC PRECAUTIONS FOR
DISASSEMBLY AND ASSEMBLY OVERHAUL INSTRUCTIONS
DISASSEMBLY
PREPARATION FOR DISASSEMBLY DISASSEMBLY
DISASSEMBLY
8 PREPARATION FOR
DISASSEMBLY
8.1 Engine oil draining1
t
Remove the drain plug from the bottom of the oil pan
and allow the oil to drain.
WARNING
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact skin.
DISASSEMBLY
9 ELECTRICAL SYSTEM
9.1 Starter
9.1.1 Testing before disassembly
1. Clearance between pinion and housing (pinion
clearance)
1) Connect the starter to a 12 volt battery as
shown in the illustration to cause the pinion to
shift into cranking position and remain there.
CAUTION
Due to the amount of current being passed through
the solenoid series winding, this test must be made
within 10 seconds.
Battery
(12 volts) Starter
0,5 to 2,0 mm
(0.020 to 0.079 in.)
2. No-load characteristics
t
Item Standard
characteristics
130 100
Current draw, A
maximum maximum
No-load
3 850 3 000
Speed, rpm
minimum minimum
3. Magnetic switch
t
Connector disconnected
CAUTION
Due to the amount of current being passed through
the solenoid series winding, this test must be made
within 10 seconds.
Figure 9 Connections for testing pull-in coil
Battery
(12 volts)
CAUTION
Due to the amount of current being passed through
the solenoid series winding, this test must be made
within 10 seconds.
Battery
(12 volts) CAUTION
Due to the amount of current being passed through
the solenoid series winding, this test must be made
within 10 seconds.
Figure 11 Connections for pinion return test
9.1.2 Removal
t
9.2 Alternator
t
Wiring incorrect
too high
Brushes worn
ELECTRICAL SYSTEM DISASSEMBLY
Ammeter
1. Connect the alternator to a 12 volt battery with an
ammeter, a voltmeter and a switch as shown in the
illustration.
Switch
2. The voltmeter reading must be zero (0) when the
starter switch is in OFF position. It must be lower
than the battery voltage when the switch is in ON
position (the engine will not start).
Voltmeter Battery 3. With one ammeter lead short-circuited, start the
(12 volts)
engine.
4. Read the voltmeter when the ammeter reading is
below five amperes and the engine is running at
Figure 14 Connections for testing voltage setting 1800 min–1 and also at 2500 min–1 with all
electrical loads turned off. The voltage setting
varies with alternator temperature. Generally, the
higher the alternator temperature, the lower the
voltage setting.
Item Standard
Ammeter
1. Disconnect the battery ground (negative) cable.
2. Connect one ammeter lead to the B terminal of the
Alternator
alternator and the other lead to the positive
Battery
indicator light
terminal of the battery. Connect one voltmeter
lead to the B terminal and the other lead to the
Switch ground.
3. Connect the battery ground cable.
4. Start the engine.
5. Turn on all electrical loads.
6. Increase the engine speed. Measure the
maximum output current at the specified alternator
Figure 15 Connections for testing output speed when the voltmeter reading is 13.5 volts.
characteristics (alternator with built-in regulator)
DISASSEMBLY ELECTRICAL SYSTEM
Standards
2 500 rpm
Output characteristics
maximum
A7T02071C
5 000 rpm
13.5 V/47 A
maximum
9.2.5 Removal
t
DISASSEMBLY
10 Cooling System
10.1 Cooling fan removal
t
Hold the fan by one hand and remove the four bolts
that hold the fan in position. Remove the fan and
spacers.
NOTE
Keep the spacers with the fan for installation.
DISASSEMBLY
11 Fuel System
11.1 Fuel injection pipe removal
t
NOTE
Put plugs or caps on the openings of the injection
pump and nozzle connectors.
NOTE
Remove the gaskets from the cylinder head with a
screwdriver or a similar tool. Discard defective
gaskets.
NOTE
Keep a record of the thickness of shims for
installation.
DISASSEMBLY
12 Lubrication System
12.1 Oil filter removal
t
DISASSEMBLY
DISASSEMBLY
removal
1. Remove the bolts that hold the rocker stays in
position and remove the rocker shaft assembly.
2. Remove the valve caps.
Front NOTE
If any parts on the cylinder head are faulty, check the
cylinder head bolts for tightness with a torque wrench
before loosening them.
removal
Lift the cylinder head straight up with a hoist.
NOTE
If the gasket is seized and the cylinder head cannot
be separated from the cylinder block, tap around the
thick side portion of the cylinder head with a plastic
hammer.
NOTE
The valves, retainers, springs and valve locks must
be set aside separately in groups, each tagged for
cylinder number, for correct installation.
NOTE
Do not reuse the valve stem seals, but replace them
by new ones.
DISASSEMBLY
WARNING
Always signal each other to prevent possible
personal injury.
WARNING
When removing the flywheel, wear heavy gloves to
avoid hand injury.
Front
Remove the bolts that hold the oil seal case in position.
Remove the case from the cylinder block with a
screwdriver or the like.
CAUTION
Do not cause damage to the oil seal.
NOTE
The valves, retainers, springs and valve locks must
be set aside separately in groups, each tagged for
cylinder number, for correct installation.
removal
Remove the lock plate and speedometer driven gear in
that order.
NOTE
Unless the speedometer driven gear is removed, the
camshaft cannot be removed.
WARNING
When removing the crankshaft pulley, be prepared to
stop the job in case the bar slips off the crankshaft to
prevent injury.
Figure 43 Removing crankshaft pulley
CAUTION
The front plate is bolted inside the timing gear case.
Do not attempt to remove this plate along with the
timing gear case by tapping.
measurement
Measure the backlash of each gear and keep a record
of it for correct installation. Replace the gears if the
backlash exceeds the limit.
Unit: mm (in.)
(0.001 6 to 0.004 7)
Idler gear and fuel
Figure 45 Measuring timing gear backlash injection pump 0.30
camshaft gear (0.011 8)
CAUTION
Do not cause damage to the lobes or bearing journals
when removing the camshaft.
removal
Remove the bolts that hold the oil pump to the cylinder
block and remove the pump.
DISASSEMBLY
16 Cylinder Block,
Crankshaft, Pistons and
Oil Pan
1. Oil pan 6. Piston pin 11. Connecting rod bearing (upper half)
2. Oil screen 7. No. 1 ring 12. Main bearing cap
3. Connecting rod cap 8. No. 2 ring 13. Main bearing (lower half)
4. Connecting rod bearing (lower half) 9. Oil ring 14. Crankshaft
(Remove 5 thru 10 as an assembly.) 10. Piston 15. Main bearing (upper half)
5. Connecting rod 16. Cylinder block
NOTE: When the cylinder block is to be discarded, remove the components (pressure relief valve, etc.) from the block for
reuse.
Cylinder Block, Crankshaft, Pistons
DISASSEMBLY and Oil Pan
CAUTION
Do not attempt to pry off the oil pan by inserting a
screwdriver or a chisel between the oil pan and
cylinder block. Damage to the oil pan can be the
result.
Loosen the nut that holds the oil screen in position and
remove the screen.
Unit: mm (in.)
crankshaft
Set a dial indicator so that it will touch the end of the
crankshaft and measure the end play. If the end play
exceeds the limit, replace No. 3 flanged bearing.
Unit: mm (in.)
1. Lay the cylinder block with its bottom (oil pan) side
up.
2. Remove the bolts that hold the main bearing caps
in position. Remove the caps.
3. Remove the front and rear bearing caps with a
sliding hammer.
CAUTION
Do not cause damage to the bearings.
NOTE
Figure 59 Removing crankshaft Put identification on each main bearing as to its
location in the engine.
connecting rod
1. Use Piston Pin Setting Tool (31A91-00100)
(special tool) to separate the piston from the
connecting rod.
2. Insert the push rod of the tool into the bore in the
t
Identification mark
Arrow mark
Piston
Tool body
CAUTION
Do not attempt to remove the piston pin by tapping.
Replace a piston pin which needs a greater force for
removal.
INSPECTION
Test
Unit: mm (in.)
Unit: mm (in.)
Nominal
Item Standard Limit
size
Unit: mm (in.)
Unit: mm (in.)
Item Limit
Unit: mm (in.)
Nominal
Item Standard Limit
size
Nominal
Item Standard Limit
size
NOTE
Before measuring the valve guides, clear the guides
of lacquer and carbon.
4. Valves
Good Bad
5. Valve refacing
Unit: mm (in.)
Width of valve seat 1.3
to 1.8 mm
(0.051 tot 0.071 in.) Item Standard Limit
7. Valve lapping
Compound
NOTE
• Do not put lapping compound on the valve stem.
• Use a lapping compound of 120 to 150 mesh for
initial lapping and a compound of finer than 200
mesh for finish lapping.
• Mixing the compound with a small amount of
Figure 77 Lapping valve in seat engine oil will help put the compound on the
valve face uniformly.
Combustion jet
INSPECTION
18.1 Camshaft
1. Clearance between journal and bushing
Unit: mm (in.)
Item Standard
Clearance between
Figure 81 Measuring camshaft journal camshaft journal and 0.15 (0.005 9)
bushing
2. Bushing replacement
Front of cylinder
block Camshaft Use Camshaft Bushing Installer (ST332340) (special
bushing
tool) for camshaft bushing replacement.
1) Removal
Remove the oil pan. Using a “remover” end of
the Installer, push out the bushing into the
cylinder block. Crush and take out the
bushing from the block.
Camshaft Bushing
Installer
2) Installation
1 mm (0.04 in.) Install a new bushing in position with its oil
holes in alignment with those of the oil gallery.
Notch in
bushing
3. Lobe lift
.Unit: mm (in.)
.Unit: mm (in.)
18.3 Tappets
1. Cam contact face
Check the cam contact face of each tappet for
abnormal wear. Replace the tappet if the face is
defective.
Item Standard
Measure the bore in the idler gear for the shaft and
the diameter of the shaft to find the clearance. If
the clearance exceeds the limit, replace the gear
or shaft whichever is badly worn.
.Unit: mm (in.)
Unit: mm (in.)
INSPECTION
19 CYLINDER BLOCK,
CRANKSHAFT,
PISTONS AND OIL PAN
CAUTION
Do not reuse crankshaft if it
shows evidence of overheating.
Scratches
Loss of
overlay
Defect
due to
poor
installation
Direction transverse
to piston pin 19.1 Pistons, Piston Rings and
Piston Pins
1. Diameter of piston
Unit: mm (in.)
0.25
78.25 78.18 to 78.20 (3.077 78.05
(0.009 8)
(3.080 7) 9 to 3.078 7) (3.072 8)
Diameter of piston oversize
78.43 to
0.50
78.50 87.45 78.30
(0.019 7)
(3.090 5) (3.087 8 to (3.082 7)
oversize
3.088 6)
.Unit: mm (in.)
NOTE
Put the piston ring in the gauge or cylinder squarely
with the piston.
.Unit: mm (in.)
.Unit: mm (in.)
Norminal
Item Standard Limit
size
22.994 to
Diameter of 23.000
23 (0.91)
piston pin (0.905 027 to
Figure 97 Measuring piston pin and bore in piston for 0.905 51)
pin
Clearance
0.006 to 0.018 0.050
between
— (0.00024 to (0.001
piston pin and
0.00071) 97)
piston
0.05/100
Bend or twist of 0.15/100
(0.002 3/4.94)
connecting rod (0.005 9/3.94)
maximum
Figure 98 Checking connecting rod for bend or twist
NOTE
To check the rod for bend, install the cap to the
connecting rod and tighten the cap nuts to the
specified torque.
Measuring diagram
3.55 ± 0.25 kgf m 19.3 Crankshaft
(25.7 ± 1.8 lbf ft)
[34.8 ± 2.5 N m]
1. Clearance between crankpin and connecting rod
bearing
Norminal
Item Standard Limit
size
47.950 to
Diameter of
48 47.965
crankpin —
(1.89) (1.887 79 to
(standard)
1.888 38)
Clearance
between 0.025 to 0.072 0.150
Figure 102 Measuring diameter of crankpin crankpin and — (0.000 98 to (0.005
connecting 0.002 83) 91)
rod bearing
Unit: mm (in.)
CAUTION
• Grind all the crankpins of one crankshaft to the
same undersize.
• Finish the crankpin fillets to a radius of 2.5 mm
2.5 mm
(0.098 in.) (0.098 in.).
.Unit: mm (in.)
Norminal
Item Standard Limit
size
51.985 to
Diameter of
52 52.000
journal —
(2.05) (2.046 65 to
(standard)
2.047 24)
Clearance
0.030 to 0.077 0.100
between
Figure 105 Measuring diameter of journal — (0.001 18 to (0.003
journal and
0.003 03) 94)
main bearing
Journal undersizes
Unit: mm (in.)
2 mm (0.08 in.) 2 mm (0.08 in.) Item Undersize Finish
0.25 0 0
51.75 (2.0374 )
(0.009 8) -0.015 -0.00059
0.50 0 0
Journal 51.50 (2.0276 )
(0.019 7) -0.015 -0.00059
0.75 0 0
51.25 (2.0177 )
(0.029 5) -0.015 -0.00059
3. Runout
Support the crankshaft on its front and rear jour-
nals in V-blocks or in a lathe and check runout at
the center journal with a dial indicator as shown in
the illustration. Depending on the amount of
runout, repair the crankshaft by grinding or by
straightening with a press. If runout exceeds the
limit, replace the crankshaft.
Unit: mm (in.)
NOTE
Do not remove the gear unless the gear or crankshaft
is defective.
Unit: mm (in.)
CAUTION
The maximum permissible amount of stock to be
removed from the cylinder head and block by grinding
is 0.2 mm (0.008 in.) in total.
ASSEMBLY
20 Cylinder Block,
Crankshaft, Pistons and
Oil pan
Force fit
Tightening torque:
5.25 ± 0.25 kgf m (38 ± 1.8 lbf ft)
[51.5 ± 2.5 N m]
Coat the entire surface with
Three Bond 1207C
Tightening torque
Cast oil pan:
2.8 ± 0.3 kgf m (20.3 ± 2.2 lbf ft)
[27.5 ± 3 N m]
Plate oil pan:
1.15 ± 0.15 kgf m (8.3 ± 1.1 lbf ft)
[11.3 ± 1.5 N m]
CAUTION
Install the front and rear bearing caps in position so
their end faces are even with the end faces of the
cylinder block.
Side seals
20.4 Side seal installation
1. Coat the side seals with Three Bond 1212.
2. Insert the side seals between the cylinder block
and the front and rear caps and push in them by
hand as far as possible, with their rounded side
Rounded side Rounded side toward the outside of the cylinder block.
4. Insert the push rod of the Tool into the bore in the
piston for the piston pin and press the pin with the
press.
CAUTION
Observe the indicator of the press when pressing the
piston pin. If the force of the press is ready to exceed
50 kgf (110 lbf) [490 N], stop pressing the pin and
check the bores in the piston and connecting rod for
alignment.
CAUTION
Do not hit the piston with a hammer to install the
piston and connecting rod. This will put force on the
piston and connecting rod and cause damage to the
piston rings and crankpin..
Piston guide
NOTE
• Make sure the number on the cap is the same as
the number on the connecting rod.
• In case of a new connecting rod having no
cylinder number, install the cap to the rod with
the notches on the same side.
NOTE
The oil screen must be installed in position so that it is
below the oil level line and away from the oil pan.
NOTE
Squeeze out a 4 mm (0.2 in.) thick bar of sealing
compound (Three Bond) from the tube and put it on
the flange of the oil pan as shown.
ASSEMBLY
Tightening torque:
1.1 ± 0.1 kgf m (8 ± 0.7 lbf ft)
[10.8 ± 1 N m]
Tightening torque:
17.5 ± 2.5 kgf m (127 ± 18 lbf ft)
[172 ± 25 N m]
Tightening torque:
6.5 ± 1 kgf m (47 ± 7 lbf ft)
[64 ± 10 N m]
Tightening torque:
13.5 ± 0.5 kgf m (98 ± 4 lbf ft)
[132 ± 5 N m]
CAUTION
Do not cause damage to the lobes and journals when
the camshaft is installed.
WARNING
Always signal each other to prevent possible
personal injury.
Figure 153 Tightening flywheel bolts
CYLINDER HEAD AND VALVE
MECHANISM ASSEMBLY
ASSEMBLY
Tightening torque:
1.15 ± 0.15 kgf m (8.3 ± 1.1 lbf ft)
[11.3 ± 1.5 N m]
Tightening torque:
1.5 ± 0.5 kgf m (11 ± 4 lbf ft) [14.7
± 5 N m]
Tightening torque:
9 ± 0.5 kgf m (65 ± 4 lbf ft)
[88 ± 5 N m]
NOTE
After scraping the gasket, rub off gasket remnants
from the face with an oilstone smeared with engine oil
and thoroughly clean the face.
NOTE
Improper stem seal installation can cause a failure to
seal against downward flow of oil along the stem.
CAUTION
Do not put excessive compression on the valve
spring. This can cause the retainer to hit and damage
the stem seal.
CAUTION
Do not use any gasket adhesive or other substances
Figure 159 Putting cylinder head gasket
on the top face of the cylinder block.
ASSEMBLY
Use a new
gasket
Use a new
gasket
Tightening torque:
1.85 ± 0.35 kgf m
(13.4 ± 2.5 lbf ft’
¨18 ± 3.4 N m*
Tightening torque:
1.85 ± 0.35 kgf m
(13.4 ± 2.5 lbf ft’
¨18 ± 3.4 N m*
ASSEMBLY
24 Fuel System
24.1 Fuel injection nozzle
Gasket
installation
1. Put the gasket on the nozzle.
2. Put the nozzle assembly in position in the cylinder
head and tighten it to the specified torque.
5.5 ± 0.5 kgf·m
Tightening torque (40 ± 4 lbf·ft)
[54 ± 5 N·m]
ASSEMBLY
25 Lubrication system
25.1 Pressure relief valve
installation
Put the relief valve in position on the cylinder block and
tighten it to the specified torque.
5 ± 0.5 kgf²m
Tightening torque (36 ± 4 lbf²ft)
[49 ± 5 N²m]
CAUTION
1. Put the sealant on the threads only.
To be coated with 2. Do not over-tighten the oil pressure switch when
thread sealant it is installed.
ASSEMBLY
26 Cooling system
26.1 Water pump installation
Put a new gasket in position on the water pump flange.
Install the water pump in position on the cylinder block.
ASSEMBLY
27 Electrical System
27.1 Glow plug installation
Install the glow plug in position in the precombustion
chamber and tighten it to the specified torque
Unit: mm (in.)
Deflection under 10 kgf 10 to 12
(22 lbf) [98 N] force (0.4 to 0.5)
Figure 181 Installing alternator
ELECTRICAL SYSTEM
28 GENERAL
28.1 Specifications (standard)1
Model A7T02071C
Model 008816-4C
Type Sheathed
Glow plug
Rated voltage, V 10.5
Model G71SP
Resistance in coil, Ω 13
Model YM-1C
Control timer
Input voltage range, V DC 9 to 15
unit
Load Solenoid (resistance in coil: 1.7 Ω minimum)
Model YMS-1
Type Solenoid
ETS type stop
Resistance in coil, Ω 1.8 ± 10% at 20°C (68°F)
solenoid
Stroke, mm (in.) 13 ± 0.5 (0.53 ± 0.02)
Operating voltage, V DC 10 to 15
Model QGS
Rated voltage, V DC 12
Operating voltage, V 7 to 15
Storage temperature
-40 to +80 (-40 to 176)
range °C (°F)
Diode
MM434-062
Glow timer
< ETS type stop solenoid >
MM201-122 Position
Pilot lamp
MM201-124
Control timer
Starter switch 0,85 mm2 or more
I6A11-14000
30890-05200 Solénoid (ETS) 2 mm2 or more
5 mm2 or more
20 mm2 or more
Battery switch
05125-00102
Fuel pump
30A60-00200 Starter relay
32A66-19100
Starter
Battery
28.2 Wiring diagrams
Diode
MM434-062
Glow timer
< ETR type stop solenoid >
Solénoid (ETR)
Controller
31A66-06100
Common (Blue)
Battery switch
05125-00102
Fuel pump
30A60-00200 Starter relay
32A66-19100 Pull in (Red)
Starter
Battery
ELECTRICAL SYSTEM
29 STARTER
29.1 Disassembly
CAUTION
The pinion must be removed before removal or
replacement of the following parts:
1. Front bracket
2. Reduction gears
3. Overrunning clutch
STARTER ELECTRICAL SYSTEM
29.1.2 Ball
The ball at the end of the armature acts as a bearing for
movement of the armature in the thrust direction. When
the armature is removed, the ball may stick to the
grease on it. Be careful not to lose the ball.
29.2 Inspection
29.2.1 Armature
1. Coil Short Circuit Test
Place the armature on a growler tester. Hold an
iron rod parallel with the armature and slowly
rotate the armature by hand. If the iron rod vibrates
or is pulled toward the armature, the armature has
a short-circuited coil and must be replaced.
3. Commutator Inspection
1) Measure the commutator’s runout using a dial
gauge. If the measurement exceeds the
specified limit, rectify the problem, making
sure that the outside diameter stays within
specification. If the surface is rough or has
stepped wear, rectify the problem with emery
paper (#300 – 500).
Unit: mm (in.)
Limit
Standard
Limit
value
Limit
Molding undercut
depth
Unit: mm (in.)
N {kgf} (lbf)
29.3 Assembly
Apply grease
Apply grease
Apply grease
Assembly sequence
16 → 12 → 13 → 14 → 15 → 1 → 10 → 11 → 9 → 8 →
5→6→7→4→3→2
STARTER ELECTRICAL SYSTEM
M-terminal
Battery (12V)
Standard value
NOTE
To prevent the solenoid switch coil from overheating,
do not energize the solenoid switch for longer than 10
seconds.
ELECTRICAL SYSTEM
30 ALTERNATOR
30.1 Disassembly
Disassembly sequence
1. Through bolt
2. Pulley
3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket
8. Stator core
9. Brush holder
10. Rectifier
11. Rear bracket
ELECTRICAL SYSTEM ALTERNATOR
CAUTION
Be careful not to insert the screwdriver too deep.
Damage to the stator core can be the result.
CAUTION
Unsolder the leads as quickly as possible to prevent
damage to the diodes in the rectifier.
Unsolder
2. Remove the screws that hold the rectifier in
position and remove the rectifier.
Figure 186 Removing stator core
ALTERNATOR ELECTRICAL SYSTEM
30.2 Inspection
30.2.1 Diodes
Trio-diodes
Heat sink (-) 1. Test the resistance between the diode and heat
sink. First touch the positive (+) prod of an
ohmmeter to the diode, then the negative (–) prod.
If the resistance is infinite in both cases, the diode
is open. If it is nearly zero in both cases, the diode
is shorted. Do the same step for the remainder of
the diodes. If any diode is open or shorted,
replace the rectifier.
30.2.4 Brushes
1. Make replacement of brushes that have been worn
down to, or beyond, the wear limit line.
Brush holder
30.3 Assembly
Follow the reverse of disassembly and use the
procedure that follows.
ELECTRICAL SYSTEM
Solenoid
1 Blue Solenoid
2 Blue Solenoid
7 Black Ground
NOTE
Coat the length of the threads to be turned in the
governor case.
NOTE
• Do not allow thread sealant to contact (A)
• Do not allow cleaning solvent to enter the
solenoid through (B)
UP CAUTION
Do not allow cleaning solvent to contact any solenoid
parts.
Water drain hole
NOTE
It will take about 10 seconds to restart an engine
which was shut down by the key shutoff device.
KEY SHUTOFF SYSTEM (ETR solenoid
type) ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
NOTE
Sealant should be applied over those threads which
are concealed when the solenoid is installed on the
cylinder block.
NOTE
It will take about 10 seconds to restart an engine
which was shut down by the key shutoff device.
AUTOMATIC GLOW SYSTEM ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
33 AUTOMATIC GLOW
SYSTEM
33.1 General
Starter switch Turning the starter switch to ON position activates the
glow plugs to heat the engine and causes the glow plug
Fuse indicator to come on.
Ammeter
Switch
Battery
Rated voltage DC 12 V
Rated voltage DC 12 V
Coil resistance 13 Ω
Item Standard
Resistance 0.55 Ω
COOLING SYSTEM
34 GENERAL
34.1 Schematic
Water pump
Radiator
Cooling fan
COOLING SYSTEM
35 INSPECTION
Test thermoswitch
and thermounit
using the
procedures that
follow.
WARNING
Water in the pan is hot. Any contact can cause
severe burns.
COOLING SYSTEM INSPECTION
Resistance at 120°C 30 mΩ
(248°F)
WARNING
Oil in the pan is hot. Any contact can cause severe
burns.
LUBRICATION SYSTEM
36 GENERAL
36.1 Schematic
Oil filter
Oil pump
Oil screen
36.2 Specifications1
Capacity (high level excl. 0.5 liter (0.13 U.S. gal) 5.7 (1.5) (with deep oil pan) 7.7 (2.0) (with deep oil pan)
of oil in oil filter), liter (U.S. gal) 3.7 (1.0 (with standard oil pan) 5.4 (1.4) (with standard oil pan)
Relief valve opening pressure 3.5 ± 0.5 kgf/cm2 (50 ± 7 psi) [343 ± 49 kPa]
LUBRICATION SYSTEM
37 INSPECTION
37.1 Oil pump
Visually check the pump for rough rotation or other
defects. Replace the pump assembly if defective.
FUEL SYSTEM
38 GENERAL
38.1 Schematic
To fuel tank
Fuel filter
overflow pipe
Fuel pump
Fuel filter
Specification
Description
S3L/S3L2 S4L/S4L2
Type Bosch M
Type Throttle
FUEL
INJECTION Model DN15PD6
NOZZLE
Injection pressure (valve opening pressure) 1400+5 kgf/cm2 (19910+71 psi) [13 7290+490 kPa]
FUEL
FILTER Type Paper element
(remote)
Table 3 Specifications
FUEL SYSTEM
39 FUEL INJECTION
NOZZLE
39.1 Inspection
39.1.1 Injection pressure (valve opening
pressure) test
1. Install the injection nozzle on the tester. Slowly
operate the tester handle to bleed (remove) air
from the tester.
2. Operate the tester handle at a speed of one stroke
per second to make a slow increase in pressure
until the valve in the injection nozzle starts to open.
Read the maximum gauge pressure at the instant
fluid flows from the tip.
3. If the injection pressure is incorrect, disassemble
Figure 215 Fuel injection nozzle ready for test the nozzle and change the thickness of the
washer.
NOTE
An increase or decrease of washer thickness by 0.1
mm (0.004 in.) will vary the injection pressure by 10
kgf/cm2 (142 psi) [981 kPa]. 10 kinds of washer are
available in thicknesses from 1.25 mm (0.049 2 in.) to
Figure 216 Removing tip from injection nozzle 1.70 mm (0.066 9 in.) in increments of 0.05 mm
(0.002 0 in.).
WARNING
When the injection nozzles are tested, be sure to
wear eye protection. Fuel comes from the orifices in
the nozzle tip with high pressure. The fuel can pierce
(go through) the skin and cause serious injury to the
operator. Keep the tip of the nozzle pointed away
from the operator and into the fuel collector.
FUEL SYSTEM FUEL INJECTION NOZZLE
CAUTION
Do not hit the tip when removing it from the injection
Needle valve nozzle.
Body
NOTE
a. Do not touch the sliding surface of the needle
valve.
b. When installing the new nozzle tip, remove
synthetic resin film from the tip and slide the
needle valve in the body in clean diesel fuel to
wash off inhibitor completely.
FUEL INJECTION NOZZLE FUEL SYSTEM
FUEL SYSTEM
Exhaust smoke 1. Check by quickly increasing engine speed under no-load No too much black or
condition. gray smoke
2. Check by starting load.
Orifice discharge patter Remove injection nozzle and reinstall it with orifice toward outside Good discharge
of engine. Look at discharge pattern by cranking the engine with pattern
starter.
40.2 Disassembly
1. Tappet guide pin
2. Lock plate
3. Tappet
4. Tappet adjusting shim
5. Lower spring seat
6. Plunger
7. Plunger spring
8. Upper spring seat
9. Control sleeve
10. Control rack
11. Delivery valve holder
12. O-ring
13. Delivery valve spring
14. Delivery valve gasket
15. Delivery valve
16. Plunger barrel
17. Pump housing
Disassembly procedure
40.2.1 Tappet removal
1. Hold the injection pump in a vise with the side that
has tappets up.
2. Straighten the lock plate away from the tappet
guide pin with a screwdriver.
3. Rotate the tappet guide pin 180° to unlock it from
the housing.
CAUTION
The tappet can be thrown from the housing when the
tappet guide pin is removed. Hold the tappet to
prevent it from falling.
CAUTION
The delivery valves are finely finished parts. Keep
them as clean as possible.
CAUTION
a. The plungers and barrels are finely finished
parts. Keep them as clean as possible.
b. Keep the plungers with their respective barrels
for installation. Do not use plungers or barrels
with other barrels or plungers.
NOTE
Adjusting plates
40.3 Inspection
40.4 Assembly
Tightening torque:
4.5±0.5 kgf·m
(32.5±4 lbf·ft) [44±5 N·m]
Figure 229 Assembly sequence Follow the reverse of disassembly and use the
procedure that follows.
Assembly procedure
40.4.1 Barrel installation
Put each barrel in position in the housing with its slot in
alignment with the dowel of the housing and put it
straight down into the bore.
Locating dowel
NOTE
If the slot in the barrel is not aligned with the dowel of
the housing, the O-ring will not seat correctly (still
visible) after the delivery valve holder has been
installed.
Valve CAUTION
Valve seat a. Any time the injection pump is disassembled, a
new O-ring must be installed.
Delivery valve b. Make sure the threads of the delivery valve
holder do not cause damage to the O-rings.
Line
CAUTION
Make sure the notch in the plunger is toward the
adjusting plate.
CAUTION
Any time the injection pump is disassembled, new
lock plates must be used.
4.5±0.5 kgf·m
(32.5±4 lbf·ft)
CAUTION
[44±5 N·m] Do not over tighten the delivery valve holders. This
can put end force on the barrels, resulting in a failure
of the plungers to move freely. If the holders are not
tightened to the specified torque, engine oil would
leak in the injection pump.
FUEL SYSTEM
41 GOVERNOR
41.1 Disassembly and inspection
Check shaft
for defects
41.2 Assembly
1. Install the levers in position.
Tie rod
Spring pin
FUEL SYSTEM
42 FUEL PUMP
42.1 Inspection
Look outside the pump for defects and test its
performance. Do not attempt to disassemble the pump.
FUEL SYSTEM
43 FUEL FILTER
1. Normally, the fuel filter is not to be disassembled.
Only element removal for cleaning or replacement
is recommended.
2. When installing the valve lever after washing, coat
Do not
remove Coat with silicone oil the O-ring for the lever with silicone oil and the
washer with grease.
Coat with grease Parts fuel filter:
1. Ring nut
Wash in diesel fuel every 2. Cup
100 sevice hours. Replace 3. O-ring
every 500 service hours 4. Element
5. Lever plate
Check for water 6. Washer
and sediment 7. Valve lever
8. O-ring
9. Packing
Figure 244 Fuel filter 10. Valve seat
11. Filter body
44 GENERAL
44.1 Schematic
Exhaust manifold
45 INSPECTION
Item Standard
MAINTENANCE
46 LUBRICATION AND
MAINTENANCE CHART
Recommended service should be performed at the
specified intervals. Under extremely severe, dusty or
wet operating conditions, more frequent lubrication
than is specified in this chart may be necessary.
Drain water and sediment from the fuel See operation manual
tank and water separator
Every 50 Service Hours
Check the battery electrolyte level and See operation manual
specific gravity
Every 100 Service Clean fuel filter element After cleaning, prime 181
Hours Clean radiator fins See operation manual
Every 250 Service Change engine oil See SPECIFICATIONS (page 16) 173
Hours or once a year
(whatever comes first) Change oil filter 173
Check and adjust valve clearance 0.25 mm (0.0098 in.) for both inlet and
175
exhaust valves
MAINTENANCE
SAE30
S A E 40
Oil viscosities S A E 15 W - 4 0
SAE10W-30
SAE5W-20
Drain plug
NOTE
“L” mark
a. After adding oil, leave the engine standing for
one minute and check the oil level.
Figure 250 Checking oil level b. Avoid mixing different brands of oils. In some
cases, they are not compatible with each other
and deteriorate when mixed. Use the same
brand at successive intervals.
c. If the engine has been left standing for a long
period of time, check the oil for level and
contamination before starting the engine. Start
and run the engine for a few minutes. Then stop
the engine and check the oil level again.
MAINTENANCE ENGINE OIL AND OIL FILTER
4. Check the new oil filter and make sure that the O-
ring is fitted in the groove. Apply a thin coat of lube
oil to the O-ring of the new oil filter.
5. Install the new filter by hand untill the O-ring
touched the base. Tighten 3/4 to 1 turn more.
Apply oil
CAUTION
Do not cause damage to the O-ring when installing
the filter.
CAUTION
Do not cause damage to the O-ring when installing
the filter.
MAINTENANCE
48 VALVE CLEARANCE
NOTE
< Front of engine Make an adjustment to the valve clearance when the
engine is cold.
Item Standard
CAUTION
After the valve clearance on the valves for all
cylinders has been adjusted, turn the crankshaft two
or three times and make sure the valve clearance is
correct.
MAINTENANCE FUEL INJECTION TIMING
MAINTENANCE
49 FUEL INJECTION
TIMING
49.1 Preparation
49.2 Inspection
49.2.1 Fuel flow method
1. Open the fuel filter valve. Turn the starter switch
key to ON position.
NOTE
Fuel will come from the injection pipe with high
pressure when the starter switch key is turned to ON
position if the engine is equipped with an electric fuel
pump. Direct fuel flow into the container.
NOTE
Turn the crankshaft in reverse direction just a little
and do Step (2) again to verify the injection timing.
49.3 Adjustment
1. If the fuel injection timing is incorrect, change the
thickness of shims under the fuel injection pump.
An increase or decrease of the shims by 0.1 mm
(0.004 in.) will vary the timing by 1°.
2. Increase the thickness of the shims to retard the
timing or decrease it to advance the timing.
Shims
Four kinds of shims are available in thicknesses
0.2 mm (0.007 9 in.), 0.3 mm (0.011 8 in.), 0.4 mm
Figure 262 Adjusting fuel injection timing (0.015 7 in.) and 0.8 mm (0.031 5 in.). These
shims have no identification; measure the thick-
TDC mark ness of each shim with a calipers before using it.
Angle by which
fuel injection
Angle by which
fuel injection
CAUTION
timing is timing is retarded Apply sealant to both faces of each shim to prevent
advanced Mark on oil leaks.
timing gear
case
3. After the timing has been adjusted, make sure it is
correct.
4. Close the fuel filter valve and restore the delivery
Increase Decrease valve and injection pipe to the original state.
shim shim
thickness. thickness.
Retarded Advanced
MAINTENANCE
50 FUEL FILTER
50.1 Fuel filter with [AIR] valve
Close the fuel filter valve. Loosen the ring nut and take
out the element for cleaning or replacement.
Valve lever
Element
Ring nut
MAINTENANCE
NOTE
The fuel system of the engine with an electric fuel
pump can be primed by turning the starter switch key
Figure 266 Priming fuel filter with [AIR] valve
to ON position.
NOTE
Turn the valve lever to OPEN position (if equipped)
Figure 267 Priming cartridge (air vent screw) type fuel before loosening any air vent screw.
filter
The fuel system of the engine with an electric fuel
pump can be primed by turning the starter switch key
to ON position.
IDLE RPM SETTING MAINTENANCE
MAINTENANCE
1. Start and run the engine at low idle until the coolant
temperature is above 60°C (140°F).
2. To set the low idle speed, loosen the lock nut for
the idling set bolt and turn the set bolt to make the
engine run at the specified rpm. Tighten the lock
nut.
3. To set the high idle speed , loosen the lock nut for
the high-idle set bolt and turn the set bolt to make
the engine run at the specified rpm. Tighten the
Idling set bolt lock nut.
MAINTENANCE
53 FUEL INJECTION
NOZZLES
53.1 Injection pressure (valve
opening pressure) test
See FUEL INJECTION NOZZLE (page 148).
53.4 Installation
1. Put the gasket on the injection nozzle.
2. Put the nozzle in position in the cylinder head and
tighten it to the specified torque.
5.5 ± 0.5 kgf·m
Tightening torque (40 ± 4 lbf·ft)
[54 ± 5 N·m
MAINTENANCE
54 FAN BELT
1. Measure the deflection of the belt. Apply 10 kgf (22
Adjusting bolt lbf) [98 N] force midway between the alternator
pulley and the crankshaft pulley.
2. Adjust the belt if the deflection is not correct.
Loosen the adjusting bolt and move the alternator
to obtain the required belt deflection.
Unit: mm(in.)
Item Standard
Deflection 10 to 12
Deflection: 10 to 12 mm (0.4 to 0.5)
(0.4 to 0.5 in.) under 10
kgf (22 lbf) [98 N] force
SERVICE DATA
55 SPECIFICATIONS1
55.1 Basic engine components
Unit: mm (in.)
27 kgf/cm2 (384
30 kgf/cm2 (427 psi)
Compression pressure psi) Repair or replace.
[2 942 kPa]
[2 648 kPa]
Valve margin (valve lip thickness) 1.0 (0.039) 0.5 (0.020) Replace valve.
Angle 45° —
Valve seat Recondition.
Width 1.3 to 1.8 (0.051 to 0.071) 2.5 (0.098)
39.1 30.5
Length under test force —
(1.54) (1.20)
Valve spring Replace.
13.9 ± 0.7 29 ± 2
Test force,
(30.6 ± 1.5) (64 ± 4.4) -15%
kgf (lbf) [N]
[136 ± 7] [284 ± 20]
Warpage of cylinder head bottom face 0.05 (0.0020) maximum 0.10 (0.003 9) Repair.
Bend (dial indicator reading) of valve push rod — 0.3 (0.012) Replace.
SERVICE DATA SPECIFICATIONS
Clearance between tappet and cylinder block — 0.15 (0.005 9) Replace tappet.
Warpage of cylinder block top face 0.05 (0.002 0) maximum 0.10 (0.003 9) Repair.
77.93 to 77.95
Standard 77.80 (3.063 0)
(3.068 1 to 3.068 9)
0.006 to 0.018
Clearance between piston pin and piston 0.050 (0.001 97)
(0.000 24 to 0.000 71)
0.06 to 0.10
No. 1 compression ring 0.30 (0.011 8)
(0.002 4 to 0.003 9)
Clearance
between 0.05 to 0.09
No. 2 compression ring 0.20 (0.007 9) Replace piston ring.
piston ring (0.002 0 to 0.003 5)
and groove
0.03 to 0.07
Oil ring 0.20 (0.007 9)
(0.001 2 to 0.002 8)
0.15 to 0.30
No. 1 compression ring
(0.005 9 to 0.011 8)
Clearance
between 0.15 to 0.35
No. 2 compression ring 1.50 (0.059) Replace piston ring
ends of (0.005 9 to 0.013 8)
piston ring
0.20 to 0.40
Oil ring
(0.007 9 to 0.015 7)
0.10 to 0.35
Thrust clearance for connecting rod big end 0.50 (0.019 7) Replace connecting rod.
(0.003 9 to 0.013 8)
51.985 to 52.000
Diameter of journal —
(2.046 65 to 2.047 24)
47.950 to 47.965
Diameter of crankpin —
(1.887 79 to 1.888 38)
a. Please refer to the applicable engine model specification sheet for actual data
1400+5 kgf/cm2
Injection pressure (valve opening pressure) (1 9910+71 psi) — Adjust with washer.
[13 7290+490 kPa]
At 50°C (122°F) 80 ± 10 Ω —
Resistance
in At 80°C (176°F) 29.5 ± 2.5 Ω — Replace.
thermounit
At 120°C (248°F) 10 ± 0.3 Ω —
0.5 to 2.0
Pinion clearance — Adjust with packing.
(0.020 to 0.079)
S3L/S3L2 S4L/S4L2
3 000 3 600
rpm —
Starter
minimum minimum
Terminal
Output At 2500 13.5 V —
voltage
charac- rpm
Alternator
SERVICE DATA
56 TIGHTENING TORQUES
56.1 Major bolts and nuts
Unit: mm (in.)
Thread, mm
Bolt or nut Torque, kgf·m (lbf·ft) [N·m]
Dia- Clamp
Pitch Width
meter length
Rocker cover bolt M8 1.25 12 40 1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5]
Crankshaft pulley nut M18 1.5 27 — 17.5 ± 2.5 (127 ± 18) [172 ± 25]
Main bearing cap bolt M10 1.25 17 81 5.25 ± 0.25 (38 ± 2) [51.5 ± 2.5]
Connecting rod cap nut M9 1.0 14 — 3.55 ± 0.25 (25.7 ± 2) [34.8 ± 2.5]
Rear plate bolt (for tractor engine) M12 1.25 17 28 9.5 ± 1 (69 ± 7) [93 ± 10]
Rear plate bolt (standard) M12 1.25 17 28 6.5 ± 1 (47 ± 7) [64 ± 10]
Rear plate bolt (stamping) M8 1.25 12 16 1.15 ± 0.15 (8.3 ± 1.1) [11.3 ± 1.5]
Oil pan bolt (for tractor engine) M8 1.25 12 25 2.8 ± 0.3 (20.3 ± 2.2) [27.5 ± 3]
Fuel leak-off pipe nut M12 1.5 18 — 2.75 ± 0.25 (20 ± 2) [27 ± 2.5]
Fuel injection nozzle holder M20 1.5 21 — 5.5 ± 0.5 (40 ± 4) [54 ± 5]
Sliding sleeve shaft M10 1.25 14 29.5 3.6 ± 0.6 (26 ± 4) [35 ± 6]
Special nut for torque spring set M12 1.0 17 — 2 ± 0.5 (14 ± 4) [20 ± 5]
Glow plug connection plate M4 0.7 8 — 0.125 ± 0.025 (0.9 ± 0.2) [1.2 ± 0.2]
Identification on head
Thread diameter
4 7
6.5 ± 1
PT 3/8 — (47 ± 7)
[64 ± 10]
SERVICE DATA SEALANTS
SERVICE DATA
57 SEALANTS
Cylinder block
Cylinder head
Force-fit parts
Dipstick guide
SERVICE DATA
58 SPECIAL TOOLS
Compression Gauge
ST332270 Compression pressure
Adaptor
measurement
NOTE
In addition to these special tools, commercially
available tools such as bearing puller, valve seat
cutting tool, valve guide installing tool, valve spring
compressing tool, oil filter wrench, etc. are necessary.
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